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Chatter in milling and other interrupted cutting operations occurs at different combinations of speed and depth of cut from chatter in continuous cutting. Prediction of stability in interrupted cutting is complicated by two facts: (1) the equation of motion when cutting is not the same as the equation when the tool is free; (2) no exact analytical solution is known when the tool is in the cut. These problems are overcome by matching the free response with an approximate solution that is valid while the tool is cutting. An approximate solution, not restricted to small times in the cut, is obtained by the application of finite elements in time. The complete, combined solution is cast in the form of a discrete map that relates position and velocity at the beginning and end of each element to the corresponding values one period earlier. The eigenvalues of the linearized map are used to determine stability. This method can be used to predict stability for arbitrary times in the cut; the current method is applicable only to a single degree of freedom. Predictions of stability for a 1-degree of freedom case are confirmed by experiment.

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Traditional regenerative stability theory predicts a set of optimally stable spindle speeds at integer fractions of the natural frequency of the most flexible mode of the system. The assumptions of this theory become invalid for highly interrupted machining, where the ratio of time spent cutting to not cutting (denoted ρ) is small. This paper proposes a new stability theory for interrupted machining that predicts a doubling in the number of optimally stable speeds as the value of ρ becomes small. The results of the theory are supported by numerical simulation and experiment. It is anticipated that the theory will be relevant for choosing optimal machining parameters in high-speed peripheral milling operations where the radial depth of cut is only a small fraction of the tool diameter.

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The implementation of high-speed machining for the manufacture of discrete parts requires accurate knowledge of the system dynamics. We describe the application of receptance coupling substructure analysis (RCSA) to the analytic prediction of the tool point dynamic response by combining frequency response measurements of individual components through appropriate connections. Experimental verification of the receptance coupling method for various tool geometries (e.g., diameter and length) and holders (HSK 63A collet and shrink fit) is given. Several experimental results are presented to demonstrate the practical applicability of the proposed method for chatter stability prediction in milling.

This paper presents the results of calibrated, microscopic measurement of the temperature fields at the tool -chip interface during the steady-state, orthogonal machining of AISI 1045 steel. The measurement system consists of an infrared imaging microscope with a 0.5 mm square target area, and a spatial resolution of less than 5 mm. The system is based on an InSb 128 Â 128 focal plane array with an allreflective microscope objective. The microscope is calibrated using a standard blackbody source from NIST. The emissivity of the machined material is determined from the infrared reflectivity measurements. Thermal images of steady state machining are measured on a diamond-turning class lathe for a range of machining parameters. The measurements are analyzed by two methods: 1) energy flux calculations made directly from the thermal images using a control -volume approach; and 2) a simplified finite-difference simulation. The standard uncertainty of the temperature measurements is ± 52°C at 800°C.

Background Despite the clinical success of modern metal-on-metal articulations, concerns with wear-related release of metal ions persist. Evidence suggests metal ion release is related to the effective coverage of the head in the metal shell (the cup's functional articular arc). A recent study suggests a reduced functional articular arc is associated with increased ion release and the arc is a function of component design, size, and the abduction angle. Questions/purposes The purposes of this study were to (1) measure the functional articular arc in different sizes of currently available one-piece metal shells from several different manufacturers; and (2) compare the functional articular arc of these one-piece metal shells with the 1808 arc of conventional hip arthroplasty acetabular components.Methods We calculated the available articular surface arc for 33 one-piece metal cups using measurements of cup depth and internal cup radius. Results The arc of the articular surface varied among manufacturers and generally decreased with decreasing shell diameter. The mean functional articular arc was 160.5°± 3.6°(range, 151.8°-165.8°), which was less than the 180°arc of a conventional acetabular component. Conclusions Our data show certain cup designs are at higher risk for failure as a result of the decreased articular surface arc. This, along with analysis of abduction angles, supports the recent findings of bearing failure with vertically placed implants. Care must be taken when implanting these shells to ensure they are placed in less abduction to avoid edge loading and the potential for early bearing failure.